How do we make safety in our processes second nature? The concept of inherent safety goes beyond simply not having materials that potentially could damage the pipes, vessels and equipment that make up manufacturing facilities. We need to understand all the ways those materials can be involved in incidents that harm people, the environment and our facilities.
Without a thorough understanding of those scenarios and how they can occur, we can’t properly evaluate the risks posed by different technological approaches and effectively apply inherently safer technologies.
In this Chemical Processing Process Safety eHandbook, we delve in to what it means to embrace the concept of inherent safety and provide tips for safer processing including:
- A variety of strategies that can eliminate hazards from operations
- Improving alarm management – how adopting a pragmatic approach can achieve significant benefits
- A rational approach to combustible dust explosion protection
From process engineers to plant managers, it is critical that everyone plays a role in implementing and adhering to energy efficient practices and exploring ways to improve energy efficiency. This special report takes an in-depth look at how organizations can increase profitability by educating and training their staff to understand the importance of energy. Topics covered include:
- Energy Saver- Educate Your Peers
- Train Your Operators on Energy Efficiency
- Train Your Project Manager on Energy Efficiency
- Train Your Plant Manager on Energy Efficiency
- Some training courses are worth the price
- Energy Saver: Do Your Own Stream Survey
- Direct Stream Injection Hot Water Systems for Jacketed Heating
- Innovation in Direct Stream Injection Heaters Since 1945
Today’s global challenges — climate change, water scarcity, food provision, declining ecosystem services, human development, and the overall transition to a sustainable society and planet — require solutions of unprecedented scale. Public policy and behavior change will play a significant role in addressing these challenges. So, too, will business and technology. In the decades ahead, these challenges offer tremendous opportunity for organizations that can contribute to tackling them.
This Chemical Processing eHandbook takes a look at how chemicals manufacturers are meeting these challenges head on. Download this Chemical Processing eHandbook for insights and strategies including:
- How organizations such as Dow, Solvay, Dupont and BP are adapting strategies for their water conservation efforts;
- How a new purification process that’s carbon-negative and energy-positive can save energy;
- Why sustainability metrics spur product development efforts to improve conservation efforts
For chemical processors, ensuring a long-lasting, high-quality mix is a huge challenge regardless of the physical properties of the mixing component – liquid, gas, solid. In this Chemical Processing Mixing eHandbook, we take a look at mixing technologies including “open” batch operation, static mixers, hydrogenation and inline mixing. Understanding how each of these technologies works, the benefits and challenges can help you to avoid common mixing mix-ups. Download your copy and learn about:
- A number of technologies that can handle pipeline mixing
- How hydrogenation reactions can achieve greater conversion rates and thus better space/time yields
- Continuous powder wetting
- Inline mixing systems
- Modern in-line mixers
Avoid common mixing mix-ups. Download your copy of this Chemical Processing Mixing eHandbook now.08/26/2015
Being armed with the knowledge on how to best care for your equipment can produce a myriad of desirable results –improved reliability of that equipment, improved quality of your production and safety for your workforce to name a few. For chemical processors and all manufacturers the benefits for proactively caring for your equipment can translate in to gains in financial performance as a result of decreasing unexpected breakdowns, downtime and maintenance costs. In this Chemical Processing Special Report we take an in-depth look at how to successfully implement an operator care program focused on caring for your plant’s equipment. We also delve deeply into rotary impingement technology and the benefits it brings to manufacturers tasked with tank cleaning to ensure reliable, uncontaminated, quality batches during production.08/25/2015
Level measurement, which is the detection of the phase split between vapor/liquid, liquid/liquid, vapor/solid and even liquid/solid, is a key parameter in the operation and control of modern industrial processes. A reliable outcome depends on the phase conditions being relatively consistent under all process conditions. Unfortunately, the importance of level control isn’t always understood. In this Chemical Processing Level Instrumentation eHandbook, we discuss best practices for level management including:
- Interpret Level Readings Right – how the type of instrument can make a big difference in deciphering measurements
- Choose the Correct Level Sensor – key considerations and questions for identifying the most appropriate choice
- Customize Your Level Detection – a myriad of options help you achieve optimal level indicator performance
It’s not uncommon for chemical processors to have hundreds of piping and flow instruments to monitor, maintain and repair. When do you slope a process line? What happens when a precision instrument drifts out of calibration? In this Chemical Processing Flow eHandbook, we look at what it takes for chemical processors to master flow challenges in several areas including:
- Piping geometry – how draining, venting, fouling and other considerations affect piping geometry
- Various methods for avoiding thermal flow meter validation pitfalls
- Piping symmetry – why designers should consider the impact of unequal flows in branches
Learn more how to avoid common piping pitfalls. Download your copy of this Chemical Processing Flow eHandbook now.07/29/2015
According to a U.S. Department of Energy survey, steam accounts for one-third of all the energy used in process plants. Monitoring and optimizing the cost of your steam system can yield big rewards. Ignoring inefficient operation easily could drain profits.
Operating and maintaining a reliable steam system is vital to chemical processing plants and can have significant cost impact on a plant's annual budget. Typical profit drainers in operating and maintaining a steam system include excessive fuel cost, inefficient steam generation, less-than-optimal steam utlilization and poor condensate recovery. This Chemical Processing Steam eHandbook presents strategies for reducing cost associated with using and generating steam, a 4 step approach for improving efficiency and insight on heat exchanger selection criteria. Specifically:
- Control Steam System Energy Costs - Steam system losses can silently drain profits
- Optimize Your Steam System - A simple four-step approach can improve steam efficiency
- Head Off Exchanger Errors - Selecting the most-appropriate heads for a shell-and-tube unit is crucial
Learn how to generate savings through steam use and generation. Download your copy of this Chemical Processing Steam eHandbook now.06/29/2015
Optimize your operation in four critical areas – production, quality, energy efficiency and safety – with pressure instrumentation. This paper reviews pressure, flow and level solutions that work across all points of the operation to minimize process variability, gain process insight, reduce maintenance and downtime, and meet regulatory demands. Learn more.06/23/2015
This article discusses process filtration approach developed for each technology stage starting from batch filtration in the lab to continuous filtration for the full-scale commercial operation. Process engineers must not “jump to conclusions”, a reference from Sherlock Holmes and Dr. John Watson who prove time and again is that there is no benefit to jumping to conclusions. Therefore, laboratory / bench top filtration testing is covered for problem analysis, technology selection and pilot and demonstration scale-up. The paper continues with the filtration testing and then scale-up to the commercial size. Finally, the paper concludes with a general review of the problem-solving skills of Holmes and Watson and how these skills can be utilized by process engineers as a framework for “idea-generation” when analyzing a new process scale-up.06/02/2015
A material’s characteristics – adhesiveness, cohesiveness, aeratibility, pressure-sensitivity – often change during processing and can cause both flow and hidden hazard challenges. And while poor flow is one of the most common problems encountered in handling or storing solids, dust control issues also need to be identified and addressed. This includes combustible dust as the repercussions can result in costly downtown and in some instances, explosions, serious injury and possibly even death. In this Chemical Processing Powder eHandbook, we take a look at strategies and solutions for taming pesky powder processing challenges including:
- Defuse Dust Dangers - Carefully consider and then counter risks of fire and explosion
- Clamp Down On Clumping - First understand what’s really causing the problem
- What You Don’t Know About Powder Flow - Shear cells can quickly reveal information about flow behavior
- Know Your Vacuum Pumps - Understand the differences between liquid ring and rotary screw dry pumps for distillation
Learn how to tame your pesky powder challenges. Download your copy of this Chemical Processing Powder eHandbook now.05/27/2015
High-pressure water jetting is powerful and versatile, helping contractors and industrial companies do hundreds of challenging jobs.
While many jobs are still done manually, new semi-automated systems can maximize three elements crucial to any company’s success: productivity, safety and environmental responsibility.05/12/2015
Thermogravimetric analyzers (TGAs) deliver valuable information about a material’s response to temperature. But while the information they deliver is critical, TGAs themselves tend to be bulky and difficult to use, and can cost tens of thousands of dollars. This paper explores how you can gather the same data as a TGA using an instrument which is considerably easier to use, more durable, and less expensive: the Computrac MAX 5000XL. The materials examined in this paper are certain flue gas desulfurization byproducts—gypsum, calcium sulfite hemihydrate, and calcium hydroxide—but the principles in question can apply to all manner of materials, from biofuels to pet food to landfill waste.
Download the white paper now.05/12/2015
For chemical processors industrial safety is a top concern. Industrial accidents can lead to lost production, injury and in some cases even death. This special report examines how organizations can reduce risk, prevent incidents and ensure safety and compliance in hazardous environments with improved processes. Topics covered include:
- How to Achieve Effective Process Safety Management (PSM) -- Senior managers play an important role in improving PSM. Their efforts should be visible and their leadership felt to ensure success.
- Getting To The Root Of Accidents -- Accident investigations usually focus on operator error or technical failures. However, applying systems thinking may provide greater insights on underlying causes and, in the long run, prevent more incidents.
- Optimizing Safety and Efficiency Through Modern Design-- This ignition protection method helps ensure accuracy, safety and compliance in hazardous environments
Optical Dissolved Oxygen Measurement in Power and Boiler Applications
Over the past decade a few trends have started to gain pace within the industry, driving a change in instrumentation requirements for operations managers and plant chemists:
- Maintenance and operations budget cuts have resulted in fewer plant personnel, forcing plant staff to optimize their workload even further
- As the cost of building new power and boiler systems increase, many operators now look to plant life extensions as a solution to bridge gaps in production capacity at a lower investment premium
These trends have changed the requirements in these applications. Starting from these trends, this article analyzes the options for oxygen measurements that are precise, reliable, stable, and above all require low to zero maintenance.04/27/2015
Process Safety Management (PSM), driven by the OSHA 1910.119 standard, aims to prevent the unwanted release of hazardous chemicals. This whitepaper presents an overview of PSM, explains the requirements of a Mechanical Integrity (MI) program, and illustrates how PSM and MI can be established within an asset management framework.04/21/2015
Issues related to physical properties, process parameters, electronic features and interconnections can all affect the flow of liquids and gases. Often working around the clock to process, transfer, and store sometimes hazardous and corrosive chemicals, processors must tackle issues related to physical properties and process parameters. In this Chemical Processing Flow eHandbook, we take a look at what it takes for chemical processors to master flow challenges for several types of materials with vastly different physical properties including:
- How non-contact ultrasonic meters can ease maintenance and improves accuracy
- Selecting the right spray nozzle - consider several factors to determine the best choice
- Why inferring internal flow rate in a column rarely makes sense
- How using Coriolis mass flowmeters provides reliable indication of gas entrainment
- Case Study: Speed Pipe Installation – when a pipe-joining system eliminates need to weld or thread connections
Learn more how to forestall flow frustrations with these best flow practices. Download your copy of this Chemical Processing Flow eHandbook now.04/15/2015
Eastman Chemicals, one of the world’s largest chemical companies, recently decided to strengthen their information security and reliability, as well as develop a path forward to lower software maintenance costs. This Case Study shows how Eastman achieved their goals by globally standardizing on Bentley's ProjectWise software in order to replace an aging, but critical, in-house records management system. The ProjectWise solution has enabled Eastman to significantly reduce their IT costs, and is helping them achieve greater security of their vital plant information while providing a modern data-centric environment to move beyond engineering records into asset performance improvement.04/14/2015
Determining what plastic tubing is best for an application can be a challenge. This report includes topics such as ingredients, temperatures, pressure and vacuum requirements, and flexibility to assist engineers and buyers with tubing and hose selection. Helps avoid costly purchasing errors.04/14/2015
While all manufacturers have standard operating procedures (SOPs) in place for quality operations, how do executives know if individuals across the company’s various business units and geographic regions are following procedure?
Global chemical manufacturers are turning to enterprise quality management systems (EQMS) to take control over quality operations. As a result, manufacturers can quickly identify and address deviations and complaints, uncover potential issues and implement global continuous quality improvements to cut up to 40% in quality management costs.
In this paper, we examine:
- The regulatory, operational and economic challenges facing chemical executives today as they work to deliver safer chemicals products in an increasingly regulated and competitive business environment
- How a disconnected approach to quality management increases risks and costs for global chemical manufacturers
- How an EQMS implemented as part of a company’s overall business strategy delivers operational and cost benefits that transform quality management from a cost center to a revenue driver